U.S. patent application number 16/490172 was filed with the patent office on 2020-03-05 for sintered polycrystalline cubic boron nitride material.
The applicant listed for this patent is Element Six (UK) Limited. Invention is credited to Antionette CAN, Anne Myriam Megne MOTCHELAHO.
Application Number | 20200071583 16/490172 |
Document ID | / |
Family ID | 58605360 |
Filed Date | 2020-03-05 |
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United States Patent
Application |
20200071583 |
Kind Code |
A1 |
CAN; Antionette ; et
al. |
March 5, 2020 |
SINTERED POLYCRYSTALLINE CUBIC BORON NITRIDE MATERIAL
Abstract
A polycrystalline cubic boron nitride, PCBN, material is
provided. The material comprises between 30 and 90 weight percent
cubic boron nitride (cBN) and a matrix material in which the cBN
particles are dispersed. The matrix material comprises particles of
an aluminium compound; the matrix material particles having a d50
when measured using a linear intercept technique of no more than
100 nm.
Inventors: |
CAN; Antionette;
(Oxfordshire, GB) ; MOTCHELAHO; Anne Myriam Megne;
(Oxfordshire, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Element Six (UK) Limited |
Oxfordshire |
|
GB |
|
|
Family ID: |
58605360 |
Appl. No.: |
16/490172 |
Filed: |
March 13, 2018 |
PCT Filed: |
March 13, 2018 |
PCT NO: |
PCT/EP2018/056174 |
371 Date: |
August 30, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C04B 35/62635 20130101;
C04B 35/62615 20130101; C04B 2235/5454 20130101; C04B 2235/3813
20130101; C04B 2235/386 20130101; C22C 2026/005 20130101; C04B
2235/608 20130101; C04B 2235/77 20130101; C04B 2235/428 20130101;
C04B 2235/5472 20130101; C04B 2235/96 20130101; B22F 3/105
20130101; C04B 2235/402 20130101; C04B 2235/6567 20130101; C22C
2026/006 20130101; C04B 2235/6565 20130101; C04B 2235/661 20130101;
C22C 2026/008 20130101; C04B 35/62625 20130101; C22C 26/00
20130101; C04B 2235/604 20130101; C04B 35/6261 20130101; C04B
2235/3804 20130101; C04B 2235/781 20130101; C04B 35/62685 20130101;
C04B 2235/3843 20130101; C04B 2235/666 20130101; C04B 2235/3817
20130101; C04B 2235/5436 20130101; C04B 2235/5445 20130101; B28B
11/243 20130101; C22C 1/10 20130101; B23B 27/148 20130101; C04B
35/5611 20130101; C04B 35/58021 20130101; C04B 35/5831 20130101;
C04B 2235/783 20130101; C04B 35/58014 20130101; C04B 2235/80
20130101; B22F 2301/00 20130101; C04B 2235/3232 20130101; C04B
2235/404 20130101; C04B 2235/656 20130101; C04B 2235/6562 20130101;
B23B 2226/18 20130101; C04B 2235/3856 20130101; C04B 35/645
20130101; C04B 2235/3865 20130101; C04B 2235/3886 20130101; C09K
3/1436 20130101; C04B 2235/3217 20130101 |
International
Class: |
C09K 3/14 20060101
C09K003/14; B28B 11/24 20060101 B28B011/24; C04B 35/5831 20060101
C04B035/5831; C04B 35/56 20060101 C04B035/56; C04B 35/58 20060101
C04B035/58; C04B 35/645 20060101 C04B035/645; C04B 35/626 20060101
C04B035/626; B23B 27/14 20060101 B23B027/14; C22C 26/00 20060101
C22C026/00; C22C 1/10 20060101 C22C001/10 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 15, 2017 |
GB |
1704133.6 |
Claims
1. A method of making a polycrystalline cubic boron nitride, PCBN,
material, the method comprising: mixing matrix precursor particles
comprising particles having an average particle size no greater
than 100 nm, the matrix precursor particles comprising an aluminium
compound, with between 30 and 90 weight percent of cubic boron
nitride, cBN, particles having an average particle size of at least
0.2 .mu.m; sintering the mixed particles at a temperature of no
less than 1000.degree. C. and no more than 2200.degree. C., and a
pressure of at least 6 GPa to form the PCBN material comprising
particles of cBN dispersed in a matrix material wherein the matrix
material particles have a d75 when measured using an equivalent
circle diameter technique of no more than 100 nm.
2. The method according to claim 1, wherein the matrix material
further comprises titanium compounds of any of carbon and
nitrogen.
3. The method according to any one of claims 1 or 2, wherein the
matrix material comprises any of titanium carbonitride, titanium
carbide, titanium nitride, titanium diboride, aluminium nitride and
aluminium oxide.
4. The method according to claims 1 or 2, further comprising
sintering at a temperature selected from any one of no more than
1700.degree. C., no more than 1600.degree. C., no more than
1500.degree. C., no more than 1400.degree. C. and no more than
1300.degree. C.
5. The method according to claims 1 or 2, wherein the step of
intimately mixing the matrix powder and the cBN powder comprises
any of wet acoustic mixing, dry acoustic mixing and attrition
milling.
6. The method according to claims 1 or 2, comprising providing cBN
particles with an average size between 0.2 and 15 .mu.m.
7. The method according to claims 1 or 2, comprising providing cBN
particles with an average size selected from any of greater than 1
.mu.m and greater than 4 .mu.m.
8. The method according to claims 1 or 2, comprising providing cBN
particles having a multi-modal average size distribution.
9. The method according to claims 1 or 2, further comprising:
sintering the mixed particles at a temperature of no less than
1000.degree. C. and no more than 2200.degree. C., and a pressure of
at least 6 GPa to form the PCBN material comprising particles of
cBN dispersed in a matrix material wherein the matrix material
particles have a d90 when measured using an equivalent circle
diameter technique of no more than 100 nm.
10. The method according to claims 1 or 2, further comprising prior
to sintering the mixed particles, compacting the mixed particles to
form a green body using any of a hand press, a cubic press and cold
isostatic pressing.
11. A polycrystalline cubic boron nitride, PCBN, material
comprising: between 30 and 90 weight percent cubic boron nitride,
cBN; a matrix material in which the cBN particles are dispersed,
the matrix material comprising particles of an aluminium compound;
wherein the matrix material particles have a d50 when measured
using a linear intercept technique of no more than 100 nm.
12. The PCBN material as claimed in claim 11, wherein the matrix
material particles have a d75 when measured using a linear
intercept technique of no more than 100 nm.
13. The PCBN material as claimed in claim 11, wherein the matrix
material particles have a d90 when measured using a linear
intercept technique of no more than 100 nm.
14. The PCBN material as claimed in claims 11 or 12, wherein the
matrix material further comprises particles comprising titanium
compounds of any of carbon and nitrogen.
15. The PCBN material as claimed in claims 11 or 12, wherein the
matrix material comprises any of titanium carbonitride, titanium
carbide, titanium nitride, titanium diboride, aluminium nitride and
aluminium oxide.
16. The PCBN material as claimed in claims 11 or 12, wherein the
cBN particles have an average size between 0.2 and 15 .mu.m.
17. The PCBN material as claimed in claims 11 or 12, wherein the
cBN particles have an average size selected from any of greater
than 1 .mu.m and greater than 4 .mu.m.
18. The PCBN material as claimed in claims 11 or 12, wherein the
cBN particles have a multi-modal average size distribution.
19. The PCBN material as claimed in claims 11 or 12, comprising no
more than 40 weight percent cBN.
20. A tool comprising a sintered polycrystalline material according
to claims 11 or 12, the tool being for any of cutting, milling,
grinding, drilling, or other abrasive applications.
Description
FIELD
[0001] The invention relates to the field of sintered
polycrystalline cubic boron nitride materials, and to methods of
making such materials.
BACKGROUND
[0002] Polycrystalline super hard materials, such as
polycrystalline diamond (PCD) and polycrystalline cubic boron
nitride (PCBN) may be used in a wide variety of tools for cutting,
machining, drilling or degrading hard or abrasive materials such as
rock, metal, ceramics, composites and wood-containing
materials.
[0003] Abrasive compacts are used extensively in cutting, milling,
grinding, drilling and other abrasive operations. They generally
contain ultrahard abrasive particles dispersed in a second phase
matrix. The matrix may be metallic or ceramic or a cermet. The
ultrahard abrasive particles may be diamond, cubic boron nitride
(cBN), silicon carbide or silicon nitride and the like. These
particles may be bonded to each other during the high pressure and
high temperature compact manufacturing process generally used,
forming a polycrystalline mass, or may be bonded via the matrix of
second phase material(s) to form a sintered polycrystalline body.
Such bodies are generally known as PCD or PCBN, where they contain
diamond or cBN as the ultra-hard abrasive, respectively.
[0004] U.S. Pat. No. 4,334,928 teaches a sintered compact for use
in a tool consisting essentially of 20 to 80 volume % of cubic
boron nitride; and the balance being a matrix of at least one
matrix compound material selected from the group consisting of a
carbide, a nitride, a carbonitride, a boride and a silicide of a
IVa or a Va transition metal of the periodic table, mixtures
thereof and their solid solution compounds. The matrix forms a
continuous bonding structure in a sintered body with the high
pressure boron nitride interspersed within a continuous matrix. The
methods outlined in this patent all involve combining the desired
materials using mechanical milling/mixing techniques such as ball
milling, mortars and the like.
[0005] Precursor powders for the matrix phase are milled to reduce
their particle size in order to be more intimately mixed and
improve the bonding between them, as smaller particles are more
reactive. However, a typical sintering process for PCBN uses a
temperature of at least 1100.degree. C. and a pressure of at least
3.5 GPa to form a PCBN material. Under these conditions, grain
growth can occur and the particle size of some of the matrix
particles can increase greatly, to have a size of typically up to 1
.mu.m. This has a detrimental effect on the properties of the
resultant PCBN.
SUMMARY
[0006] It is an object to provide a sintered PCBN material with a
more uniform matrix grain size to give improved tool
properties.
[0007] According to a first aspect, there is provided a method of
making a PCBN material. Matrix precursor particles are mixed, The
precursor powders include particles having an average particle size
no greater than 100 nm, the matrix precursor particles comprising
an aluminium compound, with between 30 and 90 weight percent of
cubic boron nitride, cBN, particles having an average particle size
of at least 0.2 .mu.m. The mixed particles are sintered at a
temperature of no less than 1000.degree. C. and no more than
2200.degree. C., and a pressure of at least 6 GPa to form the PCBN
material comprising particles of cBN dispersed in a matrix material
wherein the matrix material particles have a d50 when measured
using an equivalent circle diameter technique of no more than 100
nm.
[0008] As an option, the matrix material further comprises titanium
compounds of any of carbon and nitrogen.
[0009] As an option, the matrix material comprises any of titanium
carbonitride, titanium carbide, titanium nitride, titanium
diboride, aluminium nitride and aluminium oxide.
[0010] The method optionally further comprises sintering at a
temperature selected from any one of no more than 1700.degree. C.,
no more than 1600.degree. C., no more than 1500.degree. C., no more
than 1400.degree. C. and no more than 1300.degree. C.
[0011] The step of mixing the matrix powder and the cBN powder
optionally comprises any of wet acoustic mixing, dry acoustic
mixing and attrition milling.
[0012] As an option, cBN particles with an average size between 0.2
and 15 .mu.m are provided.
[0013] As a further option, cBN particles with an average size
selected from any of greater than 1 .mu.m and greater than 4 .mu.m
are provided.
[0014] As an option, cBN particles having a multi-modal average
size distribution are provided.
[0015] The method optionally further comprises sintering the mixed
particles at a temperature of no less than 1000.degree. C. and no
more than 2200.degree. C., and a pressure of at least 6 GPa to form
the PCBN material comprising particles of cBN dispersed in a matrix
material wherein the matrix material particles have a d90 when
measured using an equivalent circle diameter technique of no more
than 100 nm.
[0016] As an option, the method further comprises, prior to
sintering the mixed particles, compacting the mixed particles to
form a green body using any of a hand press, a cubic press and cold
isostatic pressing.
[0017] According to a second aspect, there is provided a
polycrystalline cubic boron nitride, PCBN, material comprising
between 30 and 90 weight percent cubic boron nitride, cBN, a matrix
material in which the cBN particles are dispersed, the matrix
material comprising particles of an aluminium compound, and wherein
the matrix material particles have a d50 when measured using a
linear intercept technique of no more than 100 nm.
[0018] As an option, the matrix material particles have a d75 when
measured using a linear intercept technique of no more than 100
nm.
[0019] As an option, the matrix material particles have a d90 when
measured using a linear intercept technique of no more than 100
nm.
[0020] The matrix material optionally further comprises particles
comprising titanium compounds of any of carbon and nitrogen.
[0021] As an option, the matrix material comprises any of titanium
carbonitride, titanium carbide, titanium nitride, titanium
diboride, aluminium nitride and aluminium oxide.
[0022] As an option, the cBN particles have an average size between
0.2 and 15 .mu.m. As a further option, the cBN particles have an
average size selected from any of greater than 1 .mu.m and greater
than 4 .mu.m.
[0023] The cBN particles optionally have a multi-modal average size
distribution.
[0024] As an option, the PCBN material comprises no more than 40
weight percent cBN.
[0025] According to a third aspect, there is provided a tool
comprising a sintered polycrystalline material as described above
in the second aspect, the tool being for any of cutting, milling,
grinding, drilling, or other abrasive applications.
BRIEF DESCRIPTION OF DRAWINGS
[0026] Non-limiting embodiments will now be described by way of
example and with reference to the accompanying drawings in
which:
[0027] FIG. 1 is a graph of tool life for PCBN tools sintered at
5.5 GPa and 6.8 GPa under H15 conditions;
[0028] FIG. 2 is a graph of tool life for PCBN tools sintered at
5.5 GPa and 6.8 GPa under H10 conditions;
[0029] FIG. 3 is a scanning electron micrograph of a PCBN sample
sintered at 6.8 GPa and 1300.degree. C.;
[0030] FIG. 4 is a scanning electron micrograph of a PCBN sample
sintered at 5.5 GPa and 1300.degree. C.;
[0031] FIG. 5 is a flow diagram illustrating pre-compaction
steps;
[0032] FIG. 6 shows an XRD traces of low cBN samples sintered at
different temperatures;
[0033] FIG. 7 shows an XRD traces of high cBN samples sintered at
different temperatures;
[0034] FIG. 8 shows heavy interrupted tool life of high cBN samples
sintered at different temperatures;
[0035] FIG. 9 shows XRD spectra of exemplary PCBN materials
prepared by spark plasma sintering;
[0036] FIG. 10 shows XRD spectra of further exemplary PCBN
materials prepared by spark plasma sintering;
[0037] FIG. 11 shows Vickers Hardness data for Examples 35 to
43;
[0038] FIG. 12 shows Vickers Hardness data for Examples 44 to
53;
[0039] FIG. 13 shows density data for Examples 35 to 43;
[0040] FIG. 14 shows density data for Examples 44 to 53;
[0041] FIG. 15 shows hardness data for Examples 53 to 58 and 63 to
68 sintered using SPS at 80 MPa;
[0042] FIG. 16 shows hardness data for Examples 59 to 62 and 69 to
72 sintered using SPS at 1 GPa;
[0043] FIG. 17 shows Raman spectra for various samples; and
[0044] FIG. 18 is a scanning electron micrograph prepared by spark
plasma sintering at 1 GPa.
DETAILED DESCRIPTION
[0045] It has been found that, when using fine grained matrix
precursor powders, with a d90 of less than 100 nm (when measured
using a linear intercept technique), the use of very high pressures
during sintering limits grain growth during the sintering
process.
[0046] Using the linear intercept method, a random straight line is
drawn though a micrograph and a number of grain boundaries
intersecting the line are counted. The average grain size is found
by dividing the number of intersections by the actual line length.
Averaging the results using more than one random line improves the
accuracy of the results. The average grain size is given by:
average grain size = line length number intersections
##EQU00001##
[0047] For the purpose of this analysis, five horizontal lines and
5 vertical lines were analysed for each image to obtain a linear
intercept average grain size.
[0048] Similarly, spark plasma sintering (SPS) under certain
conditions has also been found to limit grain growth. Limiting
grain growth is advantageous because smaller grains in the matrix
phase improve properties of tools made from PCBN. Such properties
include increased tool and reduced crater wear.
[0049] Considering first PCBN made using a high pressure high
temperature (HPHT) technique, it has been found that for a given
sintering temperature, a higher pressure improves performance. This
is thought to be owing to a combination of grain growth inhibition
and more effective sintering due to accelerated mass transport
during the sintering process.
[0050] A 55 vol % 1.3 .mu.m cBN content powder composition with a
matrix phase of TiC.sub.0.5N.sub.0.5 Al was prepared via an
attrition milling powder processing route. Powder was pressed into
metal cups at about 8 tonnes to create 17 mm diameter green bodies
and sintered in a belt type high pressure high temperature
apparatus.
[0051] The powders were sintered using five different sintering
cycles, as shown in Table 1. For each sintering cycle, a holding
time at the highest temperature of 19 minutes was used.
TABLE-US-00001 TABLE 1 Sample Pressure Temperature Example 1 6.8
GPa 1300.degree. C. Example 2 6.8 GPa 1450.degree. C. Example 3 5.5
GPa 1300.degree. C. Example 4 5.5 GPa 1450.degree. C. Example 5 5.0
GPa 1300.degree. C.
[0052] The sintered materials were analysed by X-ray diffraction
(XRD) and scanning electron microscopy (SEM) and found to be
well-sintered. For the Examples 1 and 3, 10.times.10 mm square
samples, 3.2 mm thick were prepared with edge chamfers and honing
to produce tools for moderately interrupted (so-called H15) hard
part machining testing. Slightly more continuous conditions were
employed (so-called H10 interrupted machining) and the same samples
were tested under these conditions with 20 passes being run on the
workpiece and the crater wear greatest depth (Kt) being measured as
an indication of so-called chemical wear.
[0053] Continuous machining is defined by a tool in continuous
contact with a workpiece for a continuous period of time, resulting
in heat and pressure generation at the tool tip. This engagement
with the workpiece results in cutting action which removes
workpiece material in chips, which flow across the surface of PCBN
tool top surface, known as the rake face. Through various
mechanisms including oxidation of the cBN, hBN formation and mass
transport from the PCBN matrix phases into the workpiece, the PCBN
tool wearing on the rake face of the tool is known as crater wear.
Due to proposed mechanisms of wear being mainly diffusional and
chemical in nature, the crater wear is often synonymous with
chemical wear. In applications where there is a higher degree of
continuous machining, lower cBN contents in the PCBN used to
machine these workpieces often perform better compared with higher
cBN content materials. This is related to hBN formation and
oxidation of the cBN in contact with hardened steel workpieces,
under the high temperature conditions at the tool-workpiece
interface.
[0054] Many cutting operations require a tool to machine parts in
continuous and interrupted modes. The gaps or spaces in the
workpiece geometry are known as interrupts and the ratio of the
length of interrupt to continuous machining, together with the
engagement angle, determine the degree of interrupt in the
machining operation.
[0055] An interrupted scale of 1-40 is defined by the continuous
applications being on the 1-5 range, 10-20 represent a moderate
interrupt in the workpiece and 25-40 represent more aggressive
interrupted conditions.
[0056] In moderately interrupted applications (H15/H20), the
chemical wear results in deep crater formation, which creates a
sharp edge at risk of chipping when the PCBN tool encounters a gap
or interrupt in the workpiece being machined. This poses a great
challenge for moderately interrupted applications, where the
success of the PCBN tool depends on a balance between chemical wear
resistance and impact resistance or strength.
[0057] Moderately interrupted machining tests (in the H15 region on
the interrupted scale) were carried out using AISI4340 hardened
steel workpieces, with six drilled holes in them, at a surface
cutting speed of 150 m/minute, with a feed rate of 0.15
mm/revolution and depth of cut 0.2 mm. PCBN tool edges were
prepared to SNMN090308 S0220 sample edge specifications, with a 20
micron hone.
[0058] Low interrupted machining tests (in the H10 region on the
interrupted scale) were carried out using similar conditions to the
H15 test but using a three-hole face rather than a six-hole
face.
[0059] FIG. 1 compares the tool life of Examples 1 and 3 when
tested using H15 conditions in a six-hole drilling test. This shows
that Example 1, which was sintered at a higher pressure than
Example 3, out-performed Example 3 by about 50%.
[0060] FIG. 2 compares the crater wear of Examples 1 and 3 when
tested using H10 conditions in a three-hole drilling test. This
shows that Example 1, which was sintered at a higher pressure than
Example 3, had significantly lower crater wear.
[0061] The Scherrer calculation method was used to relate the
breadth of XRD peaks to the size of the crystallites in the matrix
phase for Examples 1 to 5. Results shown in Table 2 indicated that
temperature was the most significant factor influencing crystallite
size of the ceramic matrix. However, it can also be seen that the
lowest crystallite size was obtained when sintering at the highest
pressure. It can be seen that temperature has more effect on
crystallite size than pressure. Note that the crystallite size may
be smaller than the grain size, as a sintered grain may consist of
more than one crystallite.
TABLE-US-00002 TABLE 2 Crystallite size Sample Temperature Position
(.degree.2.theta.) FWHM (nm) Example 1 1300.degree. C. 49.288 0.5
26 Example 2 1450.degree. C. 49.3272 0.382 37 Example 3
1300.degree. C. 49.2827 0.472 28 Example 4 1450.degree. C. 49.2628
0.394 35 Example 5 1300.degree. C. 49.3058 0.468 28
[0062] 30 vol % cBN and 45 vol % cBN content powder in a
Ti.sub.0.5N.sub.0.5 Al matrix compositions were prepared via an
attrition milling powder processing route. Powder was pressed into
metal cups at about 8 tonnes to create 17 mm diameter green bodies
and sintered in a belt type high pressure high temperature
apparatus.
[0063] Three different sintering cycles and two different cBN
contents were employed to sinter these powders, as shown in Table
3. For each example, the samples were held at maximum temperature
for 19 minutes.
TABLE-US-00003 TABLE 3 Sample cBN vol % Pressure Temperature
Example 6 30 6.8 GPa 1300.degree. C. Example 6a 45 6.8 GPa
1300.degree. C. Example 7 30 6.8 GPa 1450.degree. C. Example 7a 45
6.8 GPa 1450.degree. C. Example 8 30 5.5 GPa 1300.degree. C.
Example 8a 45 5.5 GPa 1300.degree. C.
[0064] FIG. 3 is a scanning electron micrograph of Example 6a, and
FIG. 4 is a scanning electron micrograph of Example 8a. The black
particles are cBN and the paler particles are matrix grains. It can
be seem that Example 8a, sintered at the same temperature but a
lower pressure than Example 6a, appears to have a wider spread of
large matrix grains that have grown during sintering. It can be
inferred that the use of higher pressure during sintering restricts
the growth of larger matrix grains.
[0065] These samples analysed using an SEM to estimate particle
size distributions of the ceramic matrix phases. Table 4 shows the
average particle size of the matrix phase of selected examples.
TABLE-US-00004 TABLE 4 % of matrix grains % of matrix grains Matrix
grains Sample <50 nm >50 nm, <100 nm <100 nm Example 1
50.0 28.6 d79 Example 6 37.6 29.3 d67 Example 6a 38.3 27.2 d66
Example 7a 45.5 29.5 d75 Example 8a 35.2 22.7 d58 Example 9 11.7
32.5 d44
[0066] It can be seen from Table 4 that temperature has the largest
effect of matrix phase grain size, but higher pressures can
alleviate this effect.
[0067] Three further variations were planned to develop a high
pressure synthesis route for PCBN. These variation concentrated
upon material composition and methods of pre-compaction (compaction
prior to sintering). Pre-compaction was necessary to ensure that
there was a minimized change in volume during the final sintering.
If density was not maximised before sintering, then increased
shrinkage may have led to a decrease in pressure while sintering,
resulting in conversion of cBN to hexagonal boron nitride (hBN) and
cracking of the samples.
[0068] Two variants of powder composition were chosen, one high cBN
content and one low cBN content. The high content variant (Example
9) was 90 wt % cBN with an average particle size of 10 .mu.m and 10
wt % aluminium, with an average particle size of 6 .mu.m. 81 g of
10 .mu.m cBN and 9 g of aluminium were mixed using a resonance
acoustic mixer at 80 G for 2 minutes.
[0069] The lower content variant (Example 10) was 60 vol % cBN,
with an average particle size of 1.3 .mu.m with a ceramic based
matrix of TiC.sub.0.5N.sub.0.5 with a 10% by mass addition of
aluminium to the TiC.sub.0.5N.sub.0.5 as a sintering aid. Powders
were mixed in three stages using dry acoustic mixing with Resodyn
Acoustic mixing equipment. First a matrix premix of 3.9 g aluminium
and 35.0 g TiCN, followed by a mixing of 42.2 g 1.3 .mu.m cBN. The
matrix mix was then added to the cBN pot and then mixed again. All
mixes were performed at 80 G for 2 minutes.
[0070] Three routes were chosen for pre-compaction resulting in a
three-step process: Hand compaction into ceramic cups, cold
compaction in a cubic press then finally hot compaction again in a
cubic press. However with the lower cBN content variant (Example
10), hydraulic compaction was trialled prior to cold compaction,
therefore differentiating Example 10 (hand compaction) and Example
11 (hydraulic compaction). The compaction steps are summarised in
FIG. 5.
[0071] Hydraulic compaction achieved a green body density of 2.42
g/cm.sup.3.
[0072] The ceramic cups were placed in an outer envelope and
pressed using a cubic press without any direct heating as to avoid
sintering at this stage. The samples were pressed at 600 MPa.
Samples were extracted and then hot compacted at 1300.degree. C.,
1800.degree. C. and 2000.degree. C. under a pressure of about 7
GPa.
[0073] When measuring density after hot compaction, Example 9 had a
final density of 3.36 g/cm.sup.3 and Examples 10 and 11 had a final
density of 3.67 g/cm.sup.3. The higher density is a result of the
ceramic TiC.sub.0.5N.sub.0.5 matrix and its higher density.
[0074] Slugs were removed from their hBN cups by grinding. The
resultant cylinders were then ground to a smooth finish. Following
this, they were sliced into discs using a rotating spindle and a
laser. Discs were lapped to 3.2 mm in height and 10.times.10 mm
squares were cut for wear tests. An additional piece was cut to be
polished for SEM analysis.
[0075] In the case of Examples 10 and 11, the slugs broke apart
when removed for the cups. These pieces were not recoverable for
wear tests but small pieces were analysed through SEM.
[0076] Using sintered pieces, X-ray diffraction spectra were
obtained, as shown in FIGS. 4 and 5. Owing to the difference binder
chemical compositions of Example 9 compared with Examples 10 and
11, it was not possible to make direct comparisons. However using
similar materials sintered at lower temperatures as references some
conclusions could still be drawn.
[0077] The sintering temperature alters the rates at which the cBN
reacts with the matrix phases. In the case of Examples 10 and 11,
shown in FIG. 6, it can be seen that when the sintering temperature
is increased, boride phases become prevalent, possibly due an
increased rate of diffusion of boron into the matrix phases. This
is also indicated by the reduced presence of the cBN peak at
50.7.degree. 2.theta.. There is also a reduction in the relative
intensity of AlN at higher temperature, potentially in favour of Al
forming a boride.
[0078] FIG. 7 shows the XRD spectrum of Example 9 sintered at
1300.degree. C. and 2000.degree. C. Very few differences can be
seen here, except for a large increase in the formation of AlN.
Boride phases were not detected.
[0079] FIG. 8 shows the tool life of Example 9 sintered at
1300.degree. C., 1800.degree. C. and 2000.degree. C. when tested
under highly interrupted conditions using a feed rate of 0.3 mm, a
depth of 0.2 mm, a cutting speed of 180 m/min and a workpiece
material of D2 tool steel. Samples made from material sintered at
2000.degree. C. suffered tool fracture after just 1 pass. This
highly brittle behaviour may be due to extensive reactions in the
matrix phase and excessive grain growth.
[0080] It has been found that sintering at high temperature can
alter the chemical composition of PCBN. It has further been shown
that sintering of large volume PCBN is possible if the necessary
pre-compaction steps are taken to reduce the collapse during final
sintering.
[0081] Spark Plasma Sintering (SPS) is a technique that allows
rapid sintering of PCBN. Pulsed DC current is applied to a green
body, allowing for very high heating and cooling rates. The
rapidity of the process allows rapid densification while minimizing
grain growth during the sintering process. A further advantage of
SPS when applied to PCBN is that the rapidity reduces the
conversion of cBN to hBN that would otherwise happen at relatively
low pressures (less than 3 GPa).
[0082] Initial experiments were carried out which showed that SPS
sintered samples with cBN content more than about 30 vol % and
finer than 5-10 .mu.m resulted in significant hBN formation.
[0083] Table 5 shows exemplary data for PCBN prepared using SPS at
a pressure of 80 MPa, and Table 6 shows exemplary data for PCBN
prepared using SPS at a varying pressures. All of the samples show
cBN vol % in a matrix of 85 weight % TiC/15 weight % Al, and were
carried out on a sample size of 20 mm for the 80 MPa samples and 6
mm for the other samples.
TABLE-US-00005 TABLE 5 1350 cm.sup.-1 1350 cm.sup.-1 Powder Density
hBN signal hBN signal Example cBN Sintering (gcm.sup.-3) edge
middle 12 45% 1.3 .mu.m 100.degree. C./min 1500.degree. C. 4.27 hBN
hBN 13 30% 1.3 .mu.m 500.degree. C./min 1650.degree. C. 4.04 hBN
hBN 14 30% 1.3 .mu.m 500.degree. C./min 1750.degree. C. 4.09 hBN
hBN 15 30% 1.3 .mu.m 500.degree. C./min 1850.degree. C. 4.03 Large
hBN hBN 16 45% 1.3 .mu.m 500.degree. C./min 1650.degree. C. 4.13 17
45% 1.3 .mu.m 500.degree. C./min 1750.degree. C. 4.01 hBN hBN 18
30% 1.3 .mu.m 500.degree. C./min 1850.degree. C. 3.96 hBN hBN 19
30% 10 .mu.m 500.degree. C./min 1650.degree. C. 4.42 Small No hBN
hBN 20 30% 10 .mu.m 500.degree. C./min 1750.degree. C. 4.06 Large
hBN hBN 21 30% 10 .mu.m 500.degree. C./min 1850.degree. C. 3.89
Large hBN hBN
[0084] The percentage of cBN in the powder is given as a volume
%.
[0085] FIG. 9 shows XRD spectra for Examples 12 to 21. The peak
around 31.degree. 20 arises from the hBN phase, showing that some
conversion of cBN to hBN has occurred.
[0086] Furthermore, the density data shown in Table 5 illustrate
both the degree of densification during the SPS process and also
formation of hBN, as hBN has a density of around 2.1 gcm.sup.-3 and
cBN has a density of around 3.45 gcm.sup.-3; a lower density
therefore indicates a higher degree of hBN conversion.
TABLE-US-00006 TABLE 6 1350 cm.sup.-1 1350 cm.sup.-1 Density hBN
signal hBN signal Example Powder Sintering (gcm.sup.-3) edge middle
22 30% 1.3 .mu.m 100.degree. C./min 1220.degree. C. 4.27 hBN hBN
cBN 0 minutes 750 MPa 23 30% 1.3 .mu.m 1325.degree. C. 5 mins 4.37
Large hBN hBN cBN 600 MPa 24 30% 1.3 .mu.m 1400.degree. C. 7 mins
4.21 hBN hBN cBN 600 MPa 25 30% 1.3 .mu.m 1500.degree. C. 7 mins
4.24 Large hBN hBN cBN 600 MPa 26 30% 1.3 .mu.m 1450.degree. C. 5
mins 4.18 cBN 800 MPa 27 45% 1.3 .mu.m 1300.degree. C. 5 mins 4.11
Large hBN hBN cBN 800 MPa 28 45% 1.3 .mu.m 1400.degree. C. 5 mins
4.10 hBN hBN cBN 800 MPa 29 45% 1.3 .mu.m 1480.degree. C. 5 mins
4.22 hBN hBN cBN 800 MPa 30 45% 1.3 .mu.m 1220.degree. C. 5 mins
4.57 hBN Small hBN cBN 1 GPa 31 30% 10 .mu.m 1220.degree. C. 5 mins
4.51 cBN 1 GPa 32 30% 10 .mu.m 920.degree. C. 1 min 4.35 Small hBN
Small hBN cBN 1 GPa 33 30% 10 .mu.m 850.degree. C. 5 mins 4.27
Small hBN No hBN cBN 1 GPa 34 30% 1.3 .mu.m 1110.degree. C. 5 mins
4.32 hBN hBN cBN 1 GPa
[0087] The time given in the third column of Table 6 is the time at
which the material was held at the maximum temperature, and the %
of cBN in column 2 is given as volume %.
[0088] Given the results of the PCBN compacts reported in Tables 5
and 6 and FIGS. 11 and 12, cBN content was subsequently kept no
higher than 30 vol % and an average particle size of 10 .mu.m was
used. The times and pressures of sintering were varied as shown in
Table 7.
TABLE-US-00007 TABLE 7 Heating Release Temp. max rate pressure Ex
(.degree. C.) Pressure Time (min) (.degree. C./min) (.degree. C.)
35 1650 80 MPa 2 36 1650 80 MPa 0 37 1650 80 MPa 1 38 1550 80 MPa 1
39 1550 80 MPa 2 40 1000 1 GPa 1 100 700 41 900 1 GPa 5 100 700 42
1050 1 GPa 3 100 700 43 1200 1 GPa 1 100 700 44 1650 80 MPa 2 45
1650 80 MPa 0 46 1650 80 MPa 1 47 1550 80 MPa 1 48 1550 80 MPa 2 49
1150 1 GPa 0 100 700 50 1050 1 GPa 0.5 100 700 51 1200 1 GPa 0 100
700 52 1050 1 GPa 0 100 700
[0089] Examples 35 to 52 used 30 volume % cBN. Examples 35 to 43
were prepared with a matrix of 30:70 mol Ti:Al+85% (0.5:0.5 mol
TiN:TiC), and Examples 44 to 52 were prepared using a matrix of 2:3
mol Ti:Si (metal powders) and 85% TiN/TiC. For Example 51, the
heating rate was changed to 200.degree. C./minute between the
temperatures of 1000.degree. C. and 1200.degree. C.
[0090] FIG. 11 shows Vickers Hardness data for Examples 35 to 43,
and FIG. 12 shows Vickers Hardness data for Examples 44 to 53. It
can be seen from FIG. 11 that higher pressures improve the
hardness, probably as a result of the improved densification,
whereas higher pressure in FIG. 12 lowered the hardness. This is
thought to be caused by the different binder chemistry; in this
cause the formation of residual silicon compounds may make the
material more brittle.
[0091] FIG. 13 shows density data for Examples 35 to 43, and FIG.
14 shows density data for Examples 44 to 53. The trends correspond
to the hardness trends shown in FIGS. 13 and 14.
[0092] A 30 vol % cBN content powder, comprising cBN particles with
an average particle size of 10 .mu.m was prepared by attrition
milling routes. The composition of the matrix material was 85 wt %
Ti(C.sub.0.5N.sub.0.5).sub.0.8 and 15 wt % of a combination of 70
mol % Al/30 mol % Ti. The matrix material was first heat treated at
1050.degree. C. in vacuum, followed by 4 hours of attrition milling
in hexane. The cBN was added into the attrition milling mixture and
mixed for a further 10 minutes.
[0093] The final mixture was dried and sintered in a graphite
cupping configuration in an SPS press capable at two different
pressure levels; 80 MPa and 1 GPa. The heating rates used were
100.degree. C./minute and the cooling rates 200.degree. C./minute.
Different times and maximum temperatures of SPS were used, as shown
in Table 8:
TABLE-US-00008 TABLE 8 Time at top Example Pressure (MPa) Top temp
.degree. C. temperature (min) 53 80 1450.degree. C. 2 54 80
1500.degree. C. 2 55 80 1550.degree. C. 2 56 80 1450 3 57 80 1500 3
58 80 1550 3 59 1000 1200 1 60 1000 1300 1 61 1000 1400 1 62 1000
1500 1
[0094] In order to compare a different matrix chemistry, a 30 vol %
cBN content powder, comprising cBN particles with an average
particle size of 10 .mu.m was prepared by attrition milling routes.
The composition of the matrix material was 85 wt % of a combination
of 30 mol % TiC.sub.0.8 and 70 mol % TiN.sub.0.7, together with 15
wt % of a combination of 70 mol % Al/30 mol % Ti. The matrix
material was first heat treated at 1050.degree. C. in vacuum,
followed by 4 hours of attrition milling in hexane. The cBN was
added into the attrition milling mixture and mixed for a further 10
minutes.
[0095] The final mixture was dried and sintered in a graphite
cupping configuration in an SPS press capable at two different
pressure levels; 80 MPa and 1 GPa. The heating rates used were
100.degree. C./minute and the cooling rates 200.degree. C./minute.
Different times and maximum temperatures of SPS were used, as shown
in Table 9:
TABLE-US-00009 TABLE 9 Time at top Example Pressure (MPa) Top temp
(.degree. C.) temperature (min) 63 80 1450 2 64 80 1500 2 65 80
1550 2 66 80 1450 3 67 80 1500 3 68 80 1550 3 69 1000 1200 1 70
1000 1300 1 71 1000 1400 1 72 1000 1500 1
[0096] FIG. 15 shows hardness data for Examples 53 to 58 and 63 to
68 sintered using SPS at 80 MPa. FIG. 16 shows hardness data for
Examples 59 to 62 and 69 to 72 sintered using SPS at 1 MPa. FIG. 17
shows Raman spectra for various samples. It appears that SPS using
higher pressure (1 GPa) at a moderate temp (1000.degree. C. to
1200.degree. C.) limits hBN formation, leading to improved density
and hardness.
[0097] FIG. 18 is a scanning electron micrograph of Example 62,
showing a uniform distribution of grains. Table 10 below shows
matrix grain size selected examples.
TABLE-US-00010 TABLE 10 % of matrix grains % of matrix grains
Matrix grains Sample <50 nm >50 nm, <100 nm <100 nm
Example 42 31.4 21.9 d52 Example 62 34.7 21.8 d57
[0098] Note that Example 61 and 43 were tested using an oscillating
sliding test under dray conditions with a ball-on-disc
configuration to measure wear rate, along with a similar reference
sample of 45 vol % cBN sintered in an HPHT process at 1350.degree.
C., 5.5 GPa. It was found that the reference sample had a wear rate
of 1.51.times.10.sup.-7 mm.sup.3/Nm, whereas Example 43 had a wear
rate of 3.23.times.10.sup.-8 mm.sup.3/Nm and Example 61 had a wear
rate of 2.51.times.10.sup.-8 mm.sup.3/Nm. The SPS samples therefore
had a significantly lower wear rate than the reference sample.
[0099] In general, it has been found that for both HPHT and SPS
sintering, lower temperatures inhibit grain growth. However, high
pressure has been found to improve density and also play a part in
inhibiting grain growth and enabling sintering at lower
temperatures while still inhibiting hBN conversion. When using SPS,
lower cBN content and coarser (>5 .mu.m) cBN particles have been
found to reduce conversion of hBN to cBN.
[0100] Note that Al (either in metallic or pre-reacted form) may be
coarse (>100 nm) in the matrix precursor powder for safety
reasons, leading to a higher d90 value in the precursor powder.
However, during sintering the Al melts and subsequently solidifies
with a lower particle size. For this reason, the starting powders
can have a higher d90 value than the resultant grain size of the
matrix.
Definitions
[0101] As used herein, PCBN material refers to a type of super hard
material comprising grains of cBN dispersed within a matrix
comprising metal or ceramic.
[0102] As used herein, a "PCBN structure" comprises a body of PCBN
material.
[0103] A "matrix material" is understood to mean a matrix material
that wholly or partially fills pores, interstices or interstitial
regions within a polycrystalline structure. The term "matrix
precursor powders" is used to refer to the powders that, when
subjected to a high pressure high temperature sintering process,
become the matrix material.
[0104] A multi-modal size distribution of a mass of grains is
understood to mean that the grains have a size distribution with
more than one peak, each peak corresponding to a respective "mode".
Multimodal polycrystalline bodies may be made by providing more
than one source of a plurality of grains, each source comprising
grains having a substantially different average size, and blending
together the grains or particles from the sources. In one
embodiment, a PCBN material may comprise cBN grains having a
multimodal distribution.
[0105] While this invention has been particularly shown and
described with reference to embodiments, it will be understood by
those skilled in the art that various changes in form and detail
may be made without departing from the scope of the invention as
defined by the appended claims. For example, although all of the
examples use cBN as the superhard phase, it will be appreciated
that the same techniques may be used for other types of superhard
materials dispersed in a matrix material.
* * * * *